NHTSA ID Number: 11005360
Manufacturer Communication Number: SC288_TSB_R2
TSB/Document Date: 2024-07-31
Summary
TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: FUEL TANK AND/OR PCSV CHECK VALVE INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information to inspect the fuel evaporative system and, if necessary, replace the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check valve on certain 2021-2024MY K5 (DL3a) vehicles equipped with a Gamma II 1.6L T-GDI engine, produced from March 27, 2020 through October 17, 2023. This bulletin also provides information to upgrade the ECU software logic.
GROUP
MODEL
Voluntary Emissions Service
2021-2024MY
Campaign
K5 (DL3a)
w/1.6L T-GDI
NUMBER
DATE
SC288 (Rev 2, 07/29/2024)
April 2024
VOLUNTARY EMISSIONS SERVICE CAMPAIGN
Subject:
FUEL TANK AND/OR PCSV CHECK VALVE
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
NOTICE
This bulletin has been revised to include additional information. New/revised sections of this
bulletin are indicated by a black bar in the margin area.
This bulletin provides information to inspect the fuel evaporative system and, if necessary, replace the fuel
tank and/or the Purge Control Solenoid Valve (PCSV) check valve on certain 2021-2024MY K5 (DL3a) vehicles
equipped with a Gamma II 1.6L T-GDI engine, produced from March 27, 2020 through October 17, 2023. This
bulletin also provides information to upgrade the ECU software logic. The subject vehicles may experience
fuel tank swelling due to an issue with the PCSV check valve, which results in pressurized air to flow into the
fuel tank. This may cause the Check Engine Light to illuminate, and in some cases, the engine to run rough,
and/or an inability to refuel. These conditions may cause the vehicle to release air pollutant which exceed
Federal and California standards.
Follow the procedure outlined in this publication to inspect the fuel evaporative system and, if necessary,
replace the fuel tank and/or the PCSV check valve. Before conducting the procedure, verify that the vehicle
is included in the list of affected VINs.
NOTICE
Repair status for a VIN is provided on KDealer+ (Service → Warranty Coverage → Warranty
Coverage Inquiry → Campaign Information). Not completed Recall / Service Action reports are
available on KDealer+ (Consumer Affairs → Not Completed Recall → Recall VIN → Select Report),
which includes a list of affected vehicles.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Page 2 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
Flowchart:
Follow the flowchart below to inspect and repair the vehicle. Using KDS, scan for the related DTC
P0451. A Vehicle Diagnosis Number (VDN) must be created if DTC P0451 is stored. If a VDN is not
created, Parts Ordering and Warranty claim submission issues WILL occur.
•
If the related DTC stored is not P0451, then repair the vehicle first for the existing concern.
•
After completing the repair for a Non-Related DTC, return to the flowchart below to complete
this campaign.
Vehicle In
KDS Scan:
DTC P0451
Stored?
NO
Upgrade
ECU SW
Vehicle Out
YES
Fuel Tank
Band Inspection
OK
PCSV Ck. Valve
Replacement
OK
Fuel Tank
Replacement
NG
Create Techline
Repair Assistance (RA)
Case
NG
Fuel Pump
Cover Inspection
Path 1: Vehicle IN → Related DTC stored (NO) → Upgrade ECU SW → Vehicle OUT
Path 2: Vehicle IN → Related DTC stored (YES) → Fuel Tank Band Inspection (OK) → PCSV Check Valve
Replacement → Upgrade ECU SW → Vehicle OUT
Path 3: Vehicle IN → Related DTC stored (YES) → Fuel Tank Band Inspection (NG) → Fuel Pump Cover
Inspection (OK) → Fuel Tank Replacement → PCSV Replaceemnt → Upgrade ECU SW → Vehicle OUT
Path 4: Vehicle IN → Related DTC stored (YES) → Fuel Tank Band Inspection (NG) → Fuel Pump Cover
Inspection (NG) → Open RA TL Case
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
Page 3 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
Inspection Procedure: (Fuel Tank Bands and Service Cover)
1.
Using KDS, scan the ECU on the affected
vehicle for DTC P0451:
•
IMPORTANT
If DTC P0451 is not stored, then
If the related DTC stored is not P0451,
proceed to ‘ECU Upgrade Procedure
then repair the vehicle first for the
on page 6. No further inspection is
existing concern. After completing
required.
the repair for a Non-Related DTC,
return to the flowchart below to
•
If DTC P0451 is stored, continue with
complete this campaign.
the inspection below on step 2.
Note: A Vehicle Diagnosis Number (VDN)
must be created if DTC P0451 is stored.
A
2.
Remove rear floor under covers (A).
+
Using a ruler, measure the gap between the
fuel tank (B) and BOTH fuel tank bands (C), as
shown.
3a.
C
FWD/2WD
•
B
If the gap measures 24mm or LESS
(OK), skip to complete the following:
•
1.
PCSV Check Valve (Page 10)
2.
ECU Upgrade Procedure (Page 6)
If the gap measures 25mm or MORE
(NG), proceed to step 4.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
Page 4 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
AWD/4WD
3b.
Left Hand Fuel Tank Band
•
B
If the gap measures 21mm or LESS
(OK), proceed to measure the right
hand fuel tank band.
•
C
If the gap measures 22mm or MORE
(NG), proceed to step 4.
3c.
Right Hand Fuel Tank Band
•
If the gap measures 13mm or LESS
(OK), skip to complete the following:
•
1.
PCSV Check Valve (Page 10)
2.
ECU Upgrade Procedure (Page 6)
If the gap measure 14mm or MORE
(NG), proceed to step 4.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
C
B
Page 5 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
4.
Remove the 2nd row bench seat (D) to access
the fuel pump service cover (E).
D
Note: AWD model shown on the right for
reference, the FWD models shown below
AWD/4WD
feature a single fuel tank service cover access.
FWD/2WD
E
5.
Inspect the seat floor to fuel pump service
cover (E) (4 sides) for any gaps:
•
If a gap IS NOT present (OK), the cover
is seated flush with the seat floor panel,
then proceed to replace both the PCSV
check valve (page 10) and Fuel Tank
(page 11). After completing the two
replacements,
perform
the
‘ECU
Upgrade Procedure’ (page 6).
•
If a gap IS present (NG), the cover is
lifted/detached from the seat floor
panel, then take a photo, create a
Techline Repair Assistance (RA) case,
and attach a NG photo using KVID to
the Techline case and warranty claim.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
Page 6 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
ECU Upgrade Procedure:
To correct this condition, the ECU should be reprogrammed using the KDS
download, as described in TSB SST081.
Upgrade Event Name
706.DL3a Gamma 1.6TGDI ECU Logic Improvement for Preventing Fuel Tank Pressure Increase
NOTICE
•
Confirm a fully charged battery (12.3 volts or higher is necessary) is used or utilize a fully
charged jump starter box connected to the battery.
•
Ensure the KDS is sufficiently charged at 60% or higher prior to reflash.
•
All ECU upgrades must be performed with the ignition set to the ‘ON’ position unless otherwise
stated.
•
Damaged VCI II units should not be used and promptly replaced.
•
Be careful not to disconnect the VCI-II connected to the vehicle during the ECU upgrade
procedure.
•
DO NOT start the engine during ECU upgrade.
•
DO NOT turn the ignition key ‘OFF’ or interrupt the power supply during ECU upgrade.
•
When the ECU upgrade is completed, turn the ignition ‘OFF’ and wait 10 seconds before
starting the engine.
•
ONLY use approved ECU upgrade software designated for the correct application.
IMPORTANT
It is recommended to ALWAYS check the Electronic Parts Catalog (EPC) to locate the ECU Part
Number respective to Auto/Manual Mode ROM IDs. DO NOT reference the parts label affixed to
the ECU.
NOTICE
If a ‘Communication Fail’ error notice appears or the upgrade cannot be performed, DO NOT
disconnect the KDS/VCI-II. Contact GIT America Help Desk at (888) 542-4371 or Techline.
Before attempting an ECU upgrade on any Kia
model, make sure to first determine whether the
applicable model is equipped with an immobilizer
(IMMO) security system. Failure to follow
proper procedures may cause the PCM to become inoperative after the upgrade and any claims
associated with this repair may be subject to chargeback.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
Page 7 of 15
FUEL TANK AND/OR PCSV CHECK VALVE
SUBJECT:
INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288)
ROM ID INFORMATION TABLE:
Upgrade Event #706
MY
IMMO
ISG
Yes
ISG
No
Yes
ISG
NON-ISG
Type
2WD
2WD
2WD
ECU P/No.
ROM ID
Previous
New
39121 2MKK0
TDLA1NU06F022E0K
TDLA1NU06F122E0K
TDLA1NU06F223E0K
TDLA1NU06F424E0K
TDLA1NU06F524E0K
TDLA1NU06F52FE0K
TDLA1NU06F6FBE0K
39123 2MKK0
TDLA1NU06E022E0K
TDLA1NU06E122E0K
TDLA1NU06E223E0K
TDLA1NU06E424E0K
TDLA1NU06E524E0K
TDLA1NU06E52FE0K
TDLA1NU06E6FBE0K
39121 2MKT0
TDLA1NU06F022E03
TDLA1NU06F122E03
TDLA1NU06F223E03
TDLA1NU06F424E03
TDLA1NU06F524E03
TDLA1NU06F52FE03
TDLA1NU06F6FBE03
TDLA1NU06E6FBE03
21MY
No
NON-ISG
2WD
39123 2MKT0
TDLA1NU06E022E03
TDLA1NU06E122E03
TDLA1NU06E223E03
TDLA1NU06E424E03
TDLA1NU06E524E03
TDLA1NU06E52FE03
Yes
NON-ISG
4WD
39121 2MKV0
TDLA1NU06F026K03
TDLA1NU06F126K03
TDLA1NU06F12FK03
TDLA1NU06F2FBK03
No
NON-ISG
4WD
39123 2MKV0
TDLA1NU06E026K03
TDLA1NU06E126K03
TDLA1NU06E12FK03
TDLA1NU06E2FBK03
Continued on page 6.
To verify the vehicle is affected, be sure to check the Calibration Identification of the vehicle's ECM ROM ID
and reference the Information Table as necessary.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC288 (Rev 2) K5 (DL3a) April 2024
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TSB/Document ID: SC288_TSB_R2
Replacement Service Bulletin Number:
MFR Communication Date: 2024-07-29
MFR Internal Campaign ID/Software Version: SC288
Communication Type: Emissions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
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